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Introduction
Important Safety Information
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| Illustration 1 | g02139237 |
Think Safety | |
European Union Compliant, CE marked
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.
Maintenance Section
The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal
Service Parts Section
The Service Parts section is a reference for parts identification and available part numbers.
Safety Icon Nomenclature
Personal Protection/Important Information
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| Illustration 2 | g02166423 |
Personal Protection/Important Information | |
Prohibited Action
| No smoking |
Hazard Avoidance
| Crushing hazard (foot) |
| Crushing hazard (hand) |
| Pinch point |
| Fire hazard |
| Electrical Shock - Hazard |
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| Fire hazard |
Safety Section
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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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| NOTICE |
|---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
|---|
To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills. |
General Information
Introduction
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| Illustration 3 | g02730510 |
HCS-40 Hydraulic Cylinder Servicer | |
(1) - Tail Stock
(2) - Tail Stock Chuck
(3) - Safety Strap (not shown)
(4) - Head Stock Chuck
(5) - Torque Adapter Assembly
(6) - Torque Cylinder
(7) - Hydraulic Nut Runner
(8) - Head Stock
(9) - Torque Track
(10) - Head Stock Tube
(11) - Cylinder Support
(12) - Power Sleeve
(13) - Indexing Cylinder (not shown)
(14) - Spanner
(15) - Hydraulic Power Unit
(16) - Torque Gauge
(17) - Bench Tube
(18) - Bench
(19) - Pendent Control In Holder
(20) - Oil Basin (not shown)
(21) - Oil Basin Dolly (not shown)
(22) - Pendent Cable Holder
(23) - Maximum Torque Control Valve
(24) - Manual Valve Package
(25) - Low Torque Monitor
Description
The HCS-40 Hydraulic Cylinder Servicer is a machine that disassembles and reassembles hydraulic cylinders during service and repair. With the Servicer, one person can perform all the necessary operations by using a hydraulically powered system. The equipment keeps the cylinder being serviced secured and properly aligned during every step of operation. Properly used, the HCS-40 services most cylinders without risking damage to the cylinder or injury to personnel.
The HCS-40 Hydraulic Cylinder Servicer consists of: a specialized bench with adjustable supports to hold the cylinder or separated parts, a tail stock and head stock to anchor all operations, the chucks, spanner wrench to connect the Servicer with the parts of the cylinder and a hydraulic system to provide force for the various operations. Specific parts are identified by item number in Illustration 3. The same item numbers are given in parentheses in the rest of this manual to identify parts and the parts relation to the whole machine.
Receiving
The HCS-40 Hydraulic Cylinder Servicer is shipped covered to protect the components during transit. The standard shipment consists of one transport skid and two crates. Any accessory items ordered are packed in the crates or packaged separately.
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| Illustration 4 | g02730512 |
A Servicer packed for shipment | |
Remove all strapping, packing material, and tape. Uncrate the components. Inspect the Servicer and components for shipping damage, and report any damage to the delivering carrier immediately.
Unbolt the Servicer from the skid. Before unbolting the Servicer from the skid, move the skid to the place where the Servicer will be used.
Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 1-800-542-8665, Option 1International: 1-309-578-7372Assembly Section
Installation
Positioning the Bench
- Select a level, smooth, out-of-the-way floor space.
Note: The Servicer must operate on a perfectly flat surface. Operation will not be efficient if head stock (8) cannot move by hand through Servicers range of extension. The Servicer and the cylinder may not remain aligned. Leveling can usually be done by placing shims, where necessary, under torque tracks (9) and the legs of bench (18) .
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| Illustration 5 | g02730515 |
(8) Head Stock (9) Torque Track (10) Head Stock Tube (15) Hydraulic Power Unit (18) Bench | |
- Plan for adequate space on both sides and ends of the Servicer, so the Servicer can be operated through the Servicers whole range. The space occupied by the standard HCS-40 as head stock tube (10) travels between extreme positions is shown below. Allow enough room so the operator can easily work around the Servicer. Allow room so lifting or transporting equipment can maneuver to place and remove cylinders for repair. Place the Servicer so there is more room at the stock end than at the tail stock end, if working space is limited.
- Install the Servicer beneath an overhead so large cylinders can be mounted safely and efficiently. If an overhead crane is not available, a swing beam mounted electric hoist can be helpful in mounting the larger cylinders.
- Using an 11 m (36.1 ft) chalk line, make two chalk marks exactly 787 mm (31.0 inch) apart. Run these marks in a direction that allows the Servicer to be placed with the long sides parallel to the marks and with the head stock end of bench (18) at least 8 m (26.3 ft) from the end of the marks.
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| Illustration 6 | g02730520 |
(18) Bench | |
- Set the Servicer between the chalk lines with the outer side of the bench legs at the line.
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| Illustration 7 | g02730524 |
Bench leg positioned at chalk line | |
- Using the chalk marks as a guide, lay out torque tracks (9) straight from the head stock end of the bench.
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| Illustration 8 | g02730528 |
(9) Torque Track | |
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| Illustration 9 | g02730530 |
(9) Torque Track | |
- One of the new tracks has a welded angle about half the track length. The hoses that attach to the two bulkhead fittings on the rear bench leg will run behind the angle to be protected. Be certain the track with the angle is mounted to the rear bench leg.
- Bolt each torque track to a bench leg at the head stock end of the bench. Connect the track so the mounting tab of the bench leg is against the inner side of the track.
- Connect a hold-down to head stock (8) where the hold-down will ride on each torque track. Installing the hold-downs should put the torque track and the base of the head stock in the relationship shown below
- Push head stock (8) as close to the bench. Pull the head stock out to the end of the torque tracks. If head stock tube (10) binds, shim the bench legs and/or the torque tracks to level the Servicer.
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| Illustration 10 | g02730535 |
(8) Head Stock | |
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| Illustration 11 | g02730536 |
Relation of torque tracks to base of head stock | |
- When the Servicer is level, anchor to the floor as directed in the following instructions.
Anchoring the Bench
Before the HCS-40 Hydraulic Cylinder Servicer can provide 54233 N·m (40000.0 lb ft) of torque, the Servicer must be mounted solidly to the floor.
- Line the Servicer bench up with the chalk marks where Servicer is to mount to the floor. Use the holes in the mounting pads of the bench legs as drill guides. With a 22 mm (0.07 ft) carbide bit, drill holes at least 64 mm (2.5 inch) deep in the concrete. Make sure that the bench does not move during drilling.
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| Illustration 12 | g02730541 |
Drilling anchor hole for bench leg | |
- Use the compressed air to clean cement dust out of the holes.
- Insert one of the provided Phillips anchors through the mounting pad into each drilled hole.
- Make sure that the top of the anchor is pushed down flush with the floor. Use a 7/8 in bolt, bar or other steel item, and tap with a hammer, if needed.
- Using a .68 to 1.13 kg (24 to 40 oz) hammer, expand the anchor with the provided setting tool. The anchor is properly expanded when the shoulder of the setting tool is flush with the top of the anchor.
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| Illustration 13 | g02730542 |
(26) Setting Tool (27) Mounting Pad (28) Anchor | |
- Place a 5/8 inch heavy flat washer on the 5/8 x 38 mm (1.5 inch) long hex head cap screw.
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| Illustration 14 | g02730543 |
(26) Setting Tool | |
- Screw the bolt with the washer into the anchor and torque the bolt to 108 to 122 N·m (79.7 to 90.0 lb ft). Properly installed, the anchor will have a pull-out strength of about 6804 kg (15000.2 lb).
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| Illustration 15 | g02730547 |
Tightening anchor bolt to proper torque | |
Anchoring the Tracks
- Make sure that the tracks are properly aligned with the chalk marks.
- Anchor the free end of each torque track. Use the hole in the mounting pad as a drill guide. With a 22.0 mm (0.87 inch) carbide bit, drill a hole at least 64 mm (2.5 inch) deep in the concrete. Make sure that the track does not move during drilling.
- Use compressed air to clean cement dust out of the hole.
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| Illustration 16 | g02730549 |
(9) Torque Track | |
- Insert one of the provided Phillips anchors through the mounting pad into each drilled hole.
- Make sure that the top of the anchor is pushed down flush with the floor. Use a 7/8 in bolt, bar or other steel item, and tap with a hammer, if needed.
- Using a .68 to 1.13 kg (24 to 40 oz) hammer, expand the anchor with the provided setting tool. The anchor is properly expanded when the shoulder of the setting tool is flush with the top of the anchor.
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| Illustration 17 | g02730550 |
(26) Setting Tool (27) Mounting Pad (28) Anchor | |
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| Illustration 18 | g02730551 |
(26) Setting Tool | |
- Place a 5/8 inch heavy flat washer on the 5/8 x 38 mm (1.5 inch) long hex head cap screw.
- Screw the bolt with the washer into the anchor and torque the bolt to 108 to 122 N·m (79.7 to 90.0 lb ft). Properly installed, the anchor will have a pull-out strength of about 6804 kg (15000.2 lb).
- Using the procedure used previously (refer to the ""Positioning the Bench" " Section of this manual), check for binding when the head stock is moved.
- If the head stock tube binds, make the necessary corrections in the torque tracks.
- With a spirit level, check both tracks for level throughout the track length. If the tracks are not level, loosen the bolts in the floor anchors and shim the tracks to level.
- Make sure that both tracks are lined up perfectly with the bench and are approximately 756.0 mm (29.76 inch) apart throughout the tracks length. If not, loosen the bolts in the floor anchors and shift the tracks to position properly.
- Holding the tracks in proper position, torque the bolts again to 108 to 122 N·m (79.7 to 90.0 lb ft).
- Repeat Steps 2 through 8 to anchor the remaining mounting pads.
Connecting the Hydraulic Power Unit
- Uncrate the 5 hp hydraulic power supply, which has been prewired. Position Power Supply at the tail stock end of the bench. Make sure that the pump ports are perpendicular to the four hydraulic hoses protruding from the end of the bench.
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| Illustration 19 | g02730554 |
(15) Power Unit | |
- Carefully bend the four hydraulic hoses and attach to the power unit using the number and color-coding provided.
- Uncoil pendent control (19) and the pendent prewired 8 m (26.3 ft) cable. Run cable under the bench to a point beyond the middle bench leg. Place pendent (19) in the pendent holder. Coil excess cable onto cable hook.
Note: Refer to Table 1, Color-Coding Chart.
- Reach under the bench and insert the cable into the plastic cable trough. Snap the cable holder closed.
- Fill the oil tank with 38 L (10.0 US gal) of DTE 24 hydraulic oil or equivalent.
- Have a licensed electrician wire the power unit to an appropriate electrical source.
Assembling the Portable Oil Basin
- Assemble the oil basin dolly. Bolt the caster assemblies to the cross in the inner holes.
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| Illustration 20 | g02730558 |
Oil Basin Dolly Assembly | |
- Install the oil basin, as shown.
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| Illustration 21 | g02730560 |
(20) Oil Basin (21) Oil Basin Dolly | |
Operation Section
Function of Components
The Hydraulic Cylinder Servicer allows a cylinder to be mounted on the Servicers exact center line. Mounting on center line allows hydraulic power to be used to: detorque a cap, withdraw the piston rod, detorque, and torque the piston retaining nut, reassemble the cylinder, torque the cap and and drive in the rod to give the cylinders minimum length for easy handling. The components of the Servicer are discussed in detail in the following paragraphs. Be familiar with each component and the components proper use.
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| Illustration 22 | g02730563 |
(2) Tail Stock Chuck (17) Bench Tube (18) Bench | |
To identify the location of a component, refer to the ""Description" " Section of this manual. Numbers in parentheses after the name of a component correspond with item numbers in Illustration 3 in the ""Description" " Section. For example, bench tube (17) is also identified as item number 17 in Illustration 3.
For a brief a brief outline of how a component relates to other components and fits into the servicing process, see the ""Operation Section" " of this manual.
Service Bench
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| Illustration 23 | g02730565 |
(1) Tail Stock (10) Head Stock Tube (18) Bench | |
Bench (18) is a basic weldment, which includes a permanently attached 3 m (9.8 ft) length of 102 mm (4.0 inch) square steel tubing, bench tube (17). Head stock tube (10), an 89 mm (3.5 inch) square steel beam 4 m (13.1 ft) long, can be moved hydraulically to the left or right through the bench tube. There is also a 2.5 m (8.20 ft) extension tube that mounts to the end of the 4 m (13.1 ft) tube.
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| Illustration 24 | g02730568 |
(1) Tail Stock | |
Tail stock (1) is permanently attached to the bench for maximum rigidity and strength.
Moveable tail stock chuck (2) is supported by rollers that run on the bench and a square tube that slides through the tail stock. To change the position of the chuck unlock the base, remove the locking pin from the tube, and push or pull the tube. A locking pin may be inserted into the hole nearest the end of the tube. Push or pull the pin.
The tail stock chuck has a t-slot 578.0 mm (22.76 inch) long. Two chuck wings can be inserted into the slot and secured on the center line of the cylinder under repair.
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| Illustration 25 | g02730571 |
(2) Tail Stock Chuck | |
Horizontal scales are stamped into the surface of both tail stock chuck (2), and head stock chuck. The scales are used to line up the cylinder on the center line of the Servicer. Tighten the chuck t-slot to fasten the chuck wings in place.
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| Illustration 26 | g02730574 |
Securing cone bushing in chuck wing | |
The head stock chuck wings have 44.0 mm (1.73 inch) bored holes. The Servicer includes two pairs of cone-shaped cylinder eye mounting adapters. The smaller pair, No. 930H, fits eye bushings from 25 to 89 mm (1.0 to 3.5 inch) I.D. The larger pair, No. 960H, fits eye bushings from 92 to 146 mm (3.62 to 5.75 inch) I.D. Optional pair, No. 980H, fits eye bushings from 152 to 203 mm (6.0 to 8.0 inch) I.D. The mounting adapters are secured to the chuck wings with set screws, and the barrel encapsulated between the adapters, using one of the provided 1-8 inch through bolts, tightly secured with heavy nuts and washers.
The cylinder rod eye is always mounted to tail stock chuck (2). The tail stock chuck wings are of heavier construction because higher torques are used to loosen and tighten piston retaining nuts. The tail stock chuck wings have 51 mm (2.0 inch) bored holes to accommodate the No. 930T and No. 960T mounting adapters, and the optional No. 980T set. Use the provided 1-8 inch through bolt, nuts, and washers with the No. 960T cones. Use the 1-1/2-6 inch through bolts, nuts, and washers with the No. 960T and No. 980T adapters. Storage posts are located on the tail stock end of the machine.
Adjustable Supports
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| Illustration 27 | g02730576 |
(3) Safety Strap (11) Cylinder Support | |
The two cylinder supports (11) are adjustable, up and down or sideways, by turning the two adjustment nuts. Each cylinder support has a securing plate held in place by two nuts.
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| Illustration 28 | g02730578 |
(3) Safety Strap (11) Cylinder Support | |
Both cylinder supports can be used on either the head stock tube or the bench tube.
Each cylinder support has two slots that hold safety strap (3). The strap prevents a cylinder barrel or piston rod from falling during service operations.
Spanner
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| Illustration 29 | g02730588 |
(14) Spanner (17) Bench Tube | |
Universal spanner (14) is a built-in wrench. The spanners basic function is to hold the gland retaining nut stationary while the hydraulic system of the Servicer turns the cylinder barrel. The spanner consists of two vertical steel plates mounted on the spanner base. The plates can move horizontally in a t-slot in the base. The base can be moved anywhere along the length of the bench tube (17) and secured to the tube.
The vertical plates of the spanner have two 1/2-13 inch tapped holes that are on the same plane as the cylinder center line. Spanner pins screw into these holes and fit into the slots or holes in the front face of the piston rod retaining nut.
Adapter blocks are provided so the spanner can also engage retaining caps with slots or holes on the circumference of the cap. The blocks bolt into the center-line holes of the spanner plates and hold round or square spanner pins in proper position to connect with caps.
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| Illustration 30 | g02730595 |
Use of spanner adapter blocks | |
The HCS-40 will provide much more torque than the spanner pins can resist. While Tuxco spanner pins are made from an alloy threaded rod, the pins will shear if subjected to too much force.
Head Stock
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| Illustration 31 | g02730600 |
(4) Head Stock Chuck (6) Torque Cylinder (7) Hydraulic Nut Runner (23) Maximum Torque Control Valve | |
Head Stock (8) rests on a roller supported base. The base carries head stock chuck (4), hydraulic torque (6), torque gauge (16), and hydraulic nut runner (7). The head stock chuck is mounted on a spindle which is attached to hydraulic nut runner (7) by a spline.
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| Illustration 32 | g02730605 |
(4) Head Stock Chuck | |
Secure the eye of the cylinder barrel to head stock chuck (4). Secure in the same way the eye of the piston is secured to the tail stock chuck. The spanner is positioned to keep the gland retainer or threaded barrel cap from turning while head stock chuck (4) is rotated counterclockwise. Use either hydraulic nut runner (7) or hydraulic torquing cylinder (6). The barrel unscrews from the retainer or cap. Bolts on caps do not require spanner (14).
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| Illustration 33 | g02730607 |
Barrel partially unscrewed from retaining nut | |
Hydraulic Torque
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| Illustration 34 | g02730611 |
(4) Head Stock Chuck (5) Torque Adapter Assembly (6) Torque Cylinder (7) Hydraulic Nut Runner (23) Maximum Torque Control Valve | |
Hydraulic Torque (6) is used when high torques are required to loosen barrel caps or retaining nuts. Hydraulic nut runner (7) is used when less than 5423 N·m (3999.8 lb ft) of torque is required or when hydraulic torque (6) has broken loose the barrel cap or retaining nut. Square drive socket adapters may be used to mount sockets in head stock chuck (4). Adapters are optional items available from Tuxco. For high torques, however, use No. 913. If the piston retaining nut is the square type, reverse the jaws of the No. 913 wrench.
Weld large sockets to a custom made adapter that fits the t-slot chuck, if servicing cylinders with recessed piston retaining nuts.
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| Illustration 35 | g02730614 |
No. 913 Universal High Torque T-slot Wrench | |
Hydraulic torque (6) consists of a quick connector equipped, double-acting hydraulic cylinder. The cylinder is mounted to head stock (8) with a 25 mm (1.0 inch) diameter clevis pin secured by two hitch pins. The piston rod is secured to torque adapter assembly (5) by a similar pin, also secured with two hitch pins. The torque adapter has four sets of holes to attach to head stock chuck plate. Two alloy 1 1/2 inch bars are used to make the connection.
Hydraulic torque cylinder (6) has one male and one female quick connector. The quick connectors match the connectors on the two hydraulic hoses protruding from the rear torque track. When attached to hydraulic torque cylinder (6), the piston can extend for counterclockwise torque to detorque. Retract to provide clockwise torque.
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| Illustration 36 | g02730615 |
(16) Torque Gauge | |
Torque Gauge (16), located in the top of the head stock, automatically shows and records loosening and tightening torques.
A short hydraulic hose equipped with a male and female quick connector MUST BE ATTACHED to nut runner (7) when the torquing cylinder is used. The hose allows the nut runner hydraulic motor to bypass, preventing false torque readings and damage to the hydraulic motor.
At both ends of the torque cylinder stroke, the torque gauge will show a false reading indicating the pressure of the system, not applied torque.
If a second torque stroke is required, retract the torque piston and use the second pair of holes in torque adapter assembly (5) to connect to the chuck.
Maximum torque control valve (23) is mounted underneath the nut runner bracket. The black adjustment knob protrudes from the front cover of the hydraulic nut runner mounting bracket. This valve controls the amount of torque provided by the torquing cylinder. This valve will not limit the amount of torque produced by extending the cylinder.
TO AVOID OVER TORQUING that could damage a cylinder, ALWAYS adjust torque control valve (23) before torquing. To adjust, open the valve all the way by turning the knob counterclockwise as far as possible. In this position, the hydraulic torque will provide only 2712 N·m (2000.3 lb ft) of torque.
With torque adapter assembly (5) detached from the chuck, bottom out the torquing cylinder by fully extending or retracting the piston. Turn the valve clockwise until the yellow scale reading on the gauge (16) equals the cylinder manufacturers torque specification. Attach the torque adapter assembly and proceed.
Nut Runner
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| Illustration 37 | g02730617 |
(7) Hydraulic Nut Runner (16) Torque Gauge (23) Maximum Torque Control Valve | |
Hydraulic Nut Runner (7) is attached to the head stock chuck with a splined coupling. When the HCS-40 is wired for 60 hz current, the nut runner will turn the head stock chuck clockwise and counterclockwise at approximately 7 rpm. The nut runner produces a maximum of 5423 N·m (3999.8 lb ft) of torque.
The hydraulic nut runner uses the same two hydraulic hoses that power double acting torque cylinder (6) .
Due to the power of the nut runner, service to some cylinders without using the torque cylinder, is possible.
Indexing Cylinder
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| Illustration 38 | g02730620 |
(10) Head Stock Tube (12) Power Sleeve (13) Indexing Cylinder (18) Bench | |
Telescoping head stock tube (10) is attached by a mounting plate and four 3/4 inch bolts to the head stock. The tube is moved hydraulically to the left or right through bench tube (17) to withdraw and replace piston rods.
The bench contains 1219 mm (48.0 inch) stroke hydraulic cylinder (13) mounted below bench tube (17). The rod of the cylinder extends from the head stock end of bench (18). The rod is attached with a clevis pin to power sleeve (12). There are pairs of holes drilled through the sides of head stock tube (10). A steel pin placed through the head stock tube holes allows the power sleeve to push or pull power sleeve (12) against the pin. The head stock will move away or toward bench (18) .
There is 19931 N·m (14700.3 lb ft) of force available. Always be sure that the head stock is free to move and that there are no obstructions before activating the indexing cylinder.
Pendent Control
 | |
| Illustration 39 | g02730624 |
(19) Pendent Control | |
All hydraulic circuits of the HCS-40 are controlled by switch activated, low-voltage solenoids. The switches are located in heavy-duty pendent control (19) attached to the end of an 8 m (26.3 ft) cable.
The pendent control contains six button switches that are labeled "START-STOP", "EXTEND-RETRACT", and "TORQUE-DETOTORQUE". There is a lock at the top of the pendent to prevent tampering with the HCS-40.
Function Switch Operation
START-STOP
The "START-STOP" switch on the panel box of hydraulic power unit (15) controls power. The green pendent button switch turns ON the hydraulic power unit. The red switch turns the unit OFF.
EXTEND-RETRACT
Depressing the "EXTEND" button activates indexing cylinder (13), extending the piston. The "RETRACT" button retracts the cylinder. The button must be kept depressed to function.
Micro-jogging is available by quickly pressing and releasing either button.
TORQUE-DETORQUE
This pair of buttons controls the flow of pressurized oil to the two hoses protruding from the rear torque track. Attaching the two hoses to nut runner (7) or to hydraulic torque (6), the "DETORQUE" button provides either an unscrewing function or a detorquing function. The "TORQUE" button provides either a screwing or torquing function.
Micro-jogging is available by quickly pressing and releasing either button.
Torque Tracks
The HCS-40 Hydraulic Cylinder Servicer can supply high torques to loosen the gland and piston retaining nuts. In the upper torque ranges, applied torque tends to lift the cross channel at the base of head stock (8) off torque tracks (9). The torque track and the hold-downs on the ends of the cross channel prevent lifting of the head stock assembly by torque.
A stop is provided at the end of the tracks to keep the head stock from running off the end of the torque tracks.
| NOTICE |
|---|
If the head stock is at the end of the tracks, do not apply hydraulic pressure to extend the Servicer farther. Hydraulic pressure will damage the equipment. |
Cylinder Service Procedure
Excessive pressure requirements for disassembly or assembly are caused by misalignment or bent piston rods. Servicing a bent piston rod is easier by connecting the piston rod yoke to the tail stock with a chain.
Note: The number in parentheses after the name of a Servicer component corresponds to the item numbers in Illustration 3
Preparing the Servicer
- Estimate the distance from the piston rod yoke to the piston-retaining nut in the cylinder to be serviced. Using moveable tail stock chuck (2), position the cylinder so the piston retaining nut will be beyond the head stock end of the bench. After the piston rod and the barrel are separated, reach the piston-retaining nut with a wrench. Turn the wrench with hydraulic torque (6) or nut runner (7) .
 | |
| Illustration 40 | g02730629 |
(2) Tail Stock Chuck | |
- If the piston rod has been positioned incorrectly, move the rod to the correct position. Unlock the tail stock chuck and remove the locking pin from the tube of the chuck. Push, or pull the chuck (with the piston rod attached) to the correct position, and lock the chuck in the new position.
- Prepare two cylinder supports (11) to receive the cylinder.
- If mounting the cylinder with an overhead crane (recommended) or other lifting equipment, lower the cylinder supports below the level to be used.
- If the cylinder must be moved onto the cylinder supports by hand, proceed as follows.
(1) If the piston rod is retracted (the preferred condition), position both cylinder supports under the barrel and adjust both supports to the same height.
(2) If the piston rod is extended more than about one-third of rods length, position the cylinder support with the roller under the barrel. Position the support with the wood block under the piston rod. Allow for the difference in diameter between the barrel and the rod by setting the support with the block higher.
- When the cylinder supports are in place, fasten with the securing plates.
- Measure the ID's of the barrel and piston rod eyes, and select the proper conical bushings to install in the chuck wings. Fasten item in pace with the set screws.
- Using the nut runner or hydraulic torque, turn the head stock chuck so the T-slot in the chuck is horizontal.
- Insert the chuck wings into both the head stock and tail stock chucks.
Mounting the Cylinder
- Make sure that the oil ports are open on the cylinder to be repaired.
- Move the cylinder into position on the center line of the Servicer. Position the piston rod toward tail stock (1) and the barrel toward head stock (8). A safety sling with an overhead crane with a rated capacity to raise more than the weight of the cylinder is the recommended lifting equipment.
- If using lifting equipment, position the cylinder on the center line of the Servicer and hold the cylinder in place with the sling. Proceed to Step 8 of this procedure.
- If the cylinder must be positioned by hand, have cylinder supports (11) positioned and adjusted, as explained in the ""Preparing the Servicer" " Section of this manual. Carefully move the cylinder onto the supports.
- Immediately secure the cylinder to the cylinder supports with safety straps (3) .
- Insert a through bolt through the chuck wings and yoke at each end of the cylinder. Spin a nut onto the end of each through bolt. This action will help ensure that the cylinder cannot fall during mounting operations.
- Adjust the cylinder supports to bring the center line of the cylinder up or down to the level of the Servicer center line.
- After the final adjustment to the cylinder supports, turn the nuts on the securing plates finger tight.
- Close the wings of tail stock chuck (2) so the bushings enter the rod eye.
- Fasten the through bolt tightly with the appropriate washers and nuts.
Note: The chuck wings should now be parallel to each other.
- Move the head stock so the conical bushings in the wings of the head stock chuck will fit in the barrel eye. Use the indexing cylinder.
- Secure the barrel eye following the procedures in Steps 9 and 10.
- If mounting the cylinder by hand (without the help of lifting equipment), proceed to Step 17 of this procedure.
- If mounting the cylinder with the help of lifting equipment, raise the cylinder supports until supports are pressing upward slightly on the cylinder.
Note: When a cylinder support must be adjusted upward, the securing plate must be lowered first.
- When the cylinder supports have been adjusted, turn the nuts on the securing plates finger tight.
- Immediately secure the cylinder to the cylinder supports with safety straps (3) .
 | |
| Illustration 41 | g02730634 |
(3) Safety Strap (4) Head Stock Chuck | |
- Use the left-to-right scales on the chucks to shift the ends of the cylinder horizontally. Bring the center line of the cylinder exactly onto the center line of the Servicer. The end of the cylinder will be centered when the inner surfaces of both wings are at the same numbers on the scale. For example, if one wing is at the left hand "3" on the scale, the other wing should be at the right hand "3" on the scale.
 | |
| Illustration 42 | g02730642 |
Horizontal scale on chuck | |
- Tighten the screws on each chuck to fasten the chuck wings in the t-slots.
 | |
| Illustration 43 | g02730644 |
Tightening chuck screws | |
Note: Because the cylinder may be "sagging" slightly, tighten the upper screws on the head stock chuck first.
Disassembling the Cylinder
Threaded Gland Retainer
| NOTICE |
|---|
If there are any set screws installed to keep the gland retainer from turning, make sure screws are backed out far enough for clearance. The Servicer will shear off any fastened set screw, which ruins the threads on the barrel. |
- If the gland retainer or cap is threaded, use the nut runner or torquing cylinder to turn the barrel. Make sure that the spanner holes or slots are horizontal.
- Select the proper spanner pins and install in spanner (14) .
Note: The HCS-40 will provide much more force torque than the spanner pins can resist. While Tuxco spanner pins are made from an alloy threaded rod, pins will shear if subjected to too much force. Inspect the spanner pins before each use. Replace any pins that are worn or distorted.
 | |
| Illustration 44 | g02730646 |
(14) Spanner | |
- If spanner pins of the proper size or shape are not available, make new holes. If the pin holes in the retaining nut have been damaged and will not securely hold the pins, make new holes. Carefully drill two new holes in the face of the retaining nut or the circumference of the retaining cap. Drill the two holes exactly opposite each other (exactly 180 degrees apart).
- Move the spanner so the pins slip into the holes in the retaining nut or cap. The best procedure is to insert the pin that is carried by the spanner plate nearest to the barrel. Then, if necessary, rotate the barrel slightly to permit the other pin to enter the hole in the retaining nut.
- Tighten the nuts that secure the spanner on bench tube (17). Tighten the eight bolts in the spanner base, and the bolt that locks the spanner plates together.
- Many cylinder caps require less than 5423 N·m (3999.8 lb ft) of torque to loosen. Try the nut runner first. If the cap does not break loose, switch the hoses to the hydraulic torque.
Note: If the pins shear off before the gland retainer breaks loose, try the following.
- Enlarge the holes in the retainer and use larger pins.
Show/hide table
Illustration 46 g02730656
Welding spanner plate to cap
- Tack weld the boss on the spanner plates to the nut or cap.
- Help the spanner by applying a chain wrench to the barrel and stopping the wrench handle against the bench.
- If none of these methods work, call Tuxco for other suggestions. There is a way to remove almost any retainer with the Servicer.
- Apply slight pressure against the spanner by carefully jogging the indexing cylinder.
Note: If the spanner pins "walk" out of the holes in the retaining nut or cap because the holes are worn, try the following.
- Hold the retaining nut or cap against the spanner with C-clamps or Vise-Grips.
- Drill new holes in the retaining nut or cap.
 | |
| Illustration 45 | g02730652 |
Spanner fastened in place | |
Bolted Gland Retainer
- Attempt to remove the gland retaining bolts with an impact wrench.
- If any bolt does not come loose, position the bolt so a ratchet bar and socket can be placed on the bolt. Brace the handle against the bench.
 | |
| Illustration 47 | g02730657 |
Ratchet bar positioned to loosen bolt hydraulically | |
- With the Servicer hydraulic system, loosen the bolt by turning the head stock chuck clockwise as viewed from the tail stock.
All Cylinders
- Always assume that there is oil in the cylinder being serviced. Attach a hose to each port and place the open end of the hose in the oil basin. Have the oil basin under the open end of the barrel when the piston is withdrawn. Be ready for oil to spurt out of the ports any time the piston is moved inside the barrel.
 | |
| Illustration 48 | g02730661 |
Basin positioned to catch oil | |
- When the retainer is disconnected from the barrel, use hydraulic power to drive the head stock away from the bench. This will push the barrel off the piston.
Note: Servicing a bent piston rod is easier by connecting the piston rod yoke to the tail stock with a chain.
- Remove the cylinder barrel from the machine. DO NOT CHANGE THE ADJUSTMENT OF THE SUPPORT STANDS.
Removing the Piston
- Center the wrench or adapter in the chuck.
- Snug down the chuck screws.
- Whether using a square drive adapter and socket or the No. 913 wrench, hydraulically move the head stock toward the bench. If necessary, turn the chuck until the socket or wrench engages the piston-retaining nut.
- If using the No. 913 wrench, loosen the chuck screws. Tighten the wrench on the piston retaining nut. Snug down the chuck screws again. Make sure that the wrench is centered by reading the scale on the chuck.
- Use the hydraulic torque to loosen the nut, operating the torque the same as when loosening the gland retainer. Refer to the ""Disassembling the Cylinder" " Section of this manual for precautions. Loosening and spinning off the nut with the hydraulic nut runner, may be possible.
- Back the head stock away from the piston, and remove the piston.
- If the piston is difficult to remove, use the head stock chuck to remove piston.
- Loosen the chuck screws and remove the wrench or adapter.
- Push the chuck against the end of the piston rod. Insert two short lengths of 1 1/2 inch bar in the chuck wings. Fasten the wing set screws. Tighten the wings in the chuck and pull the gland off the piston rod by carefully jogging the head stock outward.
- If the rod is not going to be polished or serviced, leave rod on the Servicer. Aligning the rod and barrel for reassembly can be done easily.
- To speed reassembly, do not change any of the support adjustments, if possible.
Reassembling the Cylinder
- If the piston rod has to be removed from the Servicer, mount the piston rod. For directions and precautions, refer to the ""Mounting the Cylinder" " Section of this manual. Make sure that the correct bushings are in the chuck wings, and follow the centering procedure. Use a magnetic level to check that the piston rod is at the correct height.
- After the cylinder has been serviced, replace the gland retaining nut or cap, the piston, and the piston-retaining nut.
- Mount the wrench or adapter with a socket in the head stock chuck.
- Engage the piston-retaining nut with a wrench or socket and use either the hydraulic torque or nut runner to tighten the nut. If using the hydraulic torque, torque can be controlled. Refer to the ""Hydraulic Torque"
" Section of this manual. If using the nut runner, the finishing torque will be approximately 5243 N·m (3867.0 lb ft)
Note: Read torque from the torque gauge while the torque cylinder is at the beginning or middle of the stroke. Readings taken at the end of the stroke result in false readings.
- Remove the wrench or adapter from the head stock chuck.
- Move the head stock out to accommodate the barrel.
- Put the roller-equipped cylinder support back onto the Servicer.
- Mount the barrel on the Servicer. For directions and precautions, refer to the ""Mounting the Cylinder" " Section of this manual. Make sure that the correct bushings are in the chuck wings. Follow the centering procedure.
- If using the Servicer to work on another cylinder after this cylinder was disassembled, make sure that alignment is correct. If any Servicer adjustment was changed while this cylinder was being repaired, make sure that alignment is correct. Check the barrel and piston rod with a magnetic level and, adjust the cylinder supports to make the barrel and piston rod perfectly level.
- Hydraulically move and jog the head stock so the piston is at, but not in, the opening of the barrel.
- Check the alignment of the piston with the opening of the barrel.
- Make vertical or diagonal adjustments by turning the nuts on the cylinder supports to align the piston rod and barrel with the piston rod. Any needed adjustments are normally made at the cylinder support that is under the barrel. Turning both nuts the same amount, in the same direction, will move the barrel straight up or straight down. Turning just one nut will move the barrel diagonally.
| NOTICE |
|---|
Align the piston rod and barrel carefully to avoid damaging the cylinder during reassembly. |
- Lubricate the piston and new seals.
- Using indexing cylinder (13), insert the piston rod into the barrel, watching carefully for any sign of binding.
Note: If there is no ramp in the barrel, use a piston ring compressor. Refer to the manufacturers instructions.
- Continue inserting the piston until the opening of the barrel meets the gland retainer. Move the cylinder support under the piston rod as necessary.
- Check alignment of the gland retainer with the opening of the barrel. Make any necessary adjustments at the cylinder support that is under the barrel.
- If the cylinder has a threaded gland retainer:
- Lubricate the threads as recommended by the manufacturer.
- Start screwing the gland retaining nut into (or cap onto) the barrel by hand. When the barrel and piston rod are perfectly aligned, the retaining nut or cap should screw on most of the way by hand. Do not start the installation of gland retainer using hydraulic power. There is no way to tell if the nut is cross-threading or if the alignment is improper.
- Complete installation of the retainer by following, in reverse order, the instructions in the ""Disassembling the Cylinder" " Section of this manual. Torque to meet the manufacturers specifications.
- If the cylinder has a bolted gland retainer:
- Lubricate the retaining bolts as recommended by the manufacturer.
- Insert the bolts and torque to meet the manufacturers specifications.
- Remove the cylinder from the Servicer by reversing the steps described in the ""Mounting the Cylinder" " Section of this manual.
Maintenance Section
Servicer Maintenance
- Check all critical Servicer components for damage and wear before each use. Replace damaged or worn components immediately.
- Check the floor mounting hardware for the bench legs and torque tracks daily to make sure that legs are securely mounted to the floor.
- Check all Servicer welds for signs of fatigue and cracks before each use.
- Keep the bottom of the head stock tube lightly greased.
- Change the hydraulic poser unit filter as indicated by the clog gauge.
- Check the hydraulic fluid level on the sight gauge weekly.
- Maintain the gear reducer per manufacturers recommendations.
For further assistance, write or call:
Tuxco Corporation4300 Grove Ave.
Gurnee, IL 60031-2155
Telephone: 847/244-2220Toll Free: 800/613-6979Fax: 847/244-7335
Attaching Hoses to HCS-40 Hydraulic Power Supply
The six hoses that provide power to the various cylinders and the nut runner on the HCS-40 are color coded. Color coding makes attaching hoses to the power unit and to the bulkhead fittings on the rear leg easy.
| Description | Color-Code |
| Indexing Cylinder Extend Hose | BLUE |
| Indexing Cylinder Retract Hose | ORANGE |
| Nut Runner Torque Hose | RED |
| Nut Runner Detorque Hose | YELLOW |
| 250' Torque Hose Extension | PURPLE |
| 250' Detorque Hose Extension | GREEN |
Installing the Hoses
- Install the YELLOW hose to the B port on the bottom valve.
- Install the ORANGE hose to the B port on the top valve.
- Install the RED hose to the A port on the bottom valve.
- Install the BLUE hose to the A port on the top valve.
- Install the GREEN hose to the bulkhead fitting that is marked B.
- Install the PURPLE hose to the bulkhead fitting that is marked A.
After the hoses have been attached to the power supply and the bulkhead fittings, proceed with Step 3 in the ""Connecting the Hydraulic Power Unit" " Section of this manual.
TUXCO WARRANTY
TUXCO CORPORATION warrants its manufactured products to be free of defective material and workmanship under normal use and service for a period of six months from time of original purchase. This warranty applies only to products which are used in accordance with all instructions as to maintenance and instruction furnished by TUXCO CORPORATION with its products.
To make a warranty claim, the product must be returned to TUXCO CORPORATION with freight prepaid. This warranty does not obligated TUXCO CORPORATION to bear any costs of labor, transportation or any other charges which may arise in connection with a warranty claim. Upon receipt of the part or parts in question, a thorough examination will be conducted to determine the cause of failure. Depending upon the results of the examination, warranty may be either granted or denied, and a speedy reply will be rendered. If warranty is denied, a report of TUXCO CORPORATION's findings will be sent to the parties involved.
TUXCO CORPORATION's liability for any damage caused by a product which fails due to defective materials or workmanship and the purchaser's exclusive remedy shall be limited to the replacement or repair if (at TUXCO CORPORATION's option) the defective part or parts as originally furnished by TUXCO CORPORATION. TUXCO CORPORATION shall not be liable for any loss, damage or expenses directly or indirectly related to the use of its products or from any other cause or for consequential damages (including, without limitation, loss of time, inconvenience, and loss of production). It is expressly understood that TUXCO CORPORATION is not responsible for damage or injury caused to other products, machinery, buildings, property, or persons by reason of the installation or use of its products.
This warranty shall not apply to products sold by TUXCO CORPORATION but manufactured in their entirety by others. Such products are warranted only to the extent of their manufacturer's warranty and whenever possible warranty claims should be handled directly with the product's manufacturer.
This warranty shall be null and void if any component of a product has been (a) tampered with, disassembled, repaired or altered (except as may be authorized by TUXCO CORPORATION in writing); (b) subjected to misuse, improper maintenance, neglect, accident, or acts of God; or (c) used for purposes for which it was not designed which may attack or harm the materials used in construction of the product or which may otherwise harm the operation of the product. Shipping damage is NOT covered by warranty. The carrier is responsible for all repair or replacement costs resulting from damage in shipment.
THIS IS TUXCO CORPORATION'S SOLE AND EXCLUSIVE WARRANTY AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHICH ARE HEREBY EXCLUDED, INCLUDING IN PARTICULAR ALL WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. No distributor or other person is authorized to assume any liability or obligation for TUXCO CORPORATION, other than expressly provided herein.